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Grinding PDF
Grinding PDF
Training Objectives
After watching the video and reviewing this printed material, the viewer will
gain knowledge and understanding of the primary industrial grinding processes.
Grinding is a material removal and surface generation process used to shape and
finish components made of metals and other materials. The precision and surface
finish obtained through grinding can be up to ten times better than with either
turning or milling.
Most abrasives used in industry are synthetic. Aluminum oxide is used in three
quarters of all grinding operations, and is primarily used to grind ferrous
metals. Next is silicon carbide, which is used for grinding softer, non-ferrous
metals and high density materials, such as cemented carbide or ceramics.
Superabrasives, namely cubic boron nitride or "CBN" and diamond, are used in
about five percent of grinding. Hard ferrous materials are ground with "CBN",
while non-ferrous materials and non-metals are best ground with diamond.
The grain size of abrasive materials is important to the process. Large, coarse
grains remove material faster, while smaller grains produce a finer finish.
Wheels are graded according their strength and wear resistance. A "hard" wheel
is one that resists the separation of its individual grains. One that is too
hard will wear slowly and present dulled grains to the work and overheat,
affecting the final finish. If too soft a wheel is used, it will deteriorate
quickly, requiring frequent replacement.
The three factors of grain size, bond type, and pore structure are closely
related, and together determine how well a wheel will perform.
Damaged wheels or even wheels suspected of being damaged should not be used.
Safety steps for proper use of grinding wheels include, but are not limited to:
Wheel dressing and truing is done with special tools designed for that purpose.
Although wheel dressing is often done manually between work cycles, some
grinding machines perform the dressing task automatically.
Types of Grinding
There are many forms of grinding, but the four major industrial grinding
processes are:
cylindrical grinding
internal grinding
centerless grinding
surface grinding
In cylindrical grinding, the workpiece rotates about a fixed axis and the
surfaces machined are concentric to that axis of rotation. Cylindrical grinding
produces an external surface that may be either straight, tapered, or contoured.
The basic components of a cylindrical grinder include a wheelhead, which
incorporate the spindle and drive motor; a cross-slide, that moves the wheelhead
to and from the workpiece; a headstock, which locates, holds, and drives the
workpiece; and a tailstock, which holds the other end of the work.
Review Questions
1. Friable means:
a. capable of resisting heat buildup
b. extremely porous
c. capable of controlled fracturing
d. tendency to clog wheel
Answer Key
1. c
2. b
3. d
4. c
5. d
6. c
7. b
8. a
Grinding Glossary
cutoff wheel A thin abrasive wheel used to cut off or slot any
material or part; usually made with an organic
bond.
driver contact Area in which driver and work touch each other.
feed reversal A slow feed of the wheel away from the work. Used
to improve the finish.
finish grind stop Stop which limits crossfeed of wheel into work.
glazed wheel A wheel with a cutting surface too smooth (or dull)
to grind efficiently. Glazing is caused by worn or
improperly dressed grains.
specific metal removal The volume of metal removed per unit of time per
rate (q') unit of effective grinding wheel width.
wheel bonds (grinding) The purpose of the bond is to hold the abrasive
grains together to form a grinding wheel. Ideally,
as the abrasive grains become dull and used, the
bonding material breaks away, thus permitting the
dull grains either to fracture or to be torn out so
that, at all times, new, sharp abrasive grains are
available for grinding the workpiece. Standard
grinding-wheel bonds are vitrified bond, silicate,
resinoid, rubber, shellac, oxychloride, and metal.